Note: Descriptions are shown in the official language in which they were submitted.
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PROTECTIVE WRAP FOR REGULATING FLUID INFILTRATION AND
METHODS OF MAKING, INSTALLING, AND USING THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[001] The present application claims the benefit of United States Provisional
Patent
Application No. 63/245,069 (pending), filed on September 16, 2021, and
entitled "Protective
Material Barrier System and Product, and Method of Using, Installing, and
Manufacturing
Protective Wrap System and Product," the entirety of which is incorporated
herein and made a
part of the present disclosure.
FIELD
[002] The present disclosure relates, generally, to protective material
barrier constructions,
such as wraps, for providing protection to surfaces, such as walls of
buildings. The present
disclosure also relates to methods of making, using, and installing such
protective material
barrier constructions.
BACKGROUND
[003] Housewrap (or house wrap) is used to protect buildings from fluid
infiltration, such as
air and water infiltration. Housewrap is typically installed on a building
between sheathing of
the building and exterior siding (e.g., bricks) of the building. Housewrap is
installed to protect
the building from weather and/or environmental elements, such as rain.
[004] There have been many different commercial protective wraps used in the
construction
of builthngs, such as residential and commercial construction. Commercial
protective wraps
are used to protect against air infiltration and damaging moisture build-up.
Air infiltration may
occur in typical construction -through, among other places, sheathing seams
and cracks around
windows and doors. Moisture build-up can occur externally in the wall cavity
from, for
example, leaking exterior finishes or coverings, and cracks around windows and
doors.
[005] Commercial protective wraps are typically used as secondary weather
barriers in
buildings behind exterior finishes or coverings such as siding, brick, stone,
masonry, stucco
and concrete veneers. Stucco may be synthetic based (e.g., a polymer-based
stucco) or
cementitious (a mixture of Portland cement, lime and sand). One type of stucco
system, exterior
insulation finish system (drainage UPS), typically involves using a drainage
plane, an
insulation board, and a wire or synthetic mesh_ that accepts a cemeinitious
coating. in stucco
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systems, protective wraps are not typically installed directly in contact with
the cementitious
coatings.
[006] Both woven and non-woven commercial protective wraps are commonly used
in the
construction of buildings. The strength properties of woven wraps are
typically much higher
than the strength properties of non-woven wraps. Some woven wraps are
translucent, which
assists in locating studs, as well as window and door openings. Non-woven
wraps, however,
generally have higher permea.bilities than woven wraps.
[007] Commercial protective wraps, such as non-woven wraps, woven-wraps and
cross-
laminated wraps, also may be micro-perforated so as to allow moisture vapor to
pass
therethrough. Most non-woven commercial protective wraps (such as spun bonded
polyelefin
wraps.) are not perforated, however, because the processes used in forming the
wraps result in
a structure that inherently allows the moisture vapor to pass through the
wrap.
[008] It would be desirable to have a protective wrap that provides for
improved fluid
handling as well as additional improved features.
BRIEF SUMMARY
10091 In one aspect, a material barrier systems, apparatus, or product a
system or barrier is
provided that incorporates cross-woven or cross-laminate materials as an
integral layer, and,
preferably, a layered portion comprising such cross-laminate or cross-woven
materials.
[0010/ Some embodiments include a protective drainage wrap. The wrap includes
a base web
haying cross-woven or cross-laminate tape elements including first tape
elements extending in
a drainage direction and second tape elements extending in a direction that is
transverse to the
drainage direction. The base web presents a. front surface and a back surface
respectively
defining a _hunt and back. of the base web. A plurality of spaced apart,
elongated drainage
strands are supported on the front of the web and extending in the drainage
direction, wherein
the strands are hydrophilic.
[001 1 Some embodiments include a protective drainage wrap for placement
intermediate a
structure and an external environment. A frontward direction and a backward
direction
respectively corresponds to a direction toward the external environment and an
opposite
direction toward the structure. The wrap includes a base web including cross-
woven or cross-
laminate tape elements including first tape elements extending in a drainage
direction and
second tape elements extending in a direction transverse to the drainage
direction. The tape
elements together present a continuous front surface of the base web and a
back surface of the
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web. A plurality of spaced apart, elongated drainage strands are supported
frontward of the
front surface of the base web and extending in the drainage direction.
100121 Some embodiments include a protective drainage wrap. The wrap includes
a base web
including a cross-woven or cross-laminate tape elements including first tape
elements
extending in a drainage direction and second tape elements extending in a
direction transverse
to the drainage direction. A front surface of said base web is characterized
by a plurality of
spaced apart troughs each extending in the drainage direction.
[001.31 Some embodiments include a protective drainage wrap including a base
web including
cross-woven or cross-laminate tape elements including first tape elements
extending in a.
drainage direction and second tape elements extending in a direction
transverse to the drainage
direction. The base web presents a back surface and a front surface. A vapor-
permeable and
liquid impermeable barrier layer is situated adjacent the back surface of the
base web. A
nonwoven layer is situated on a back surface of said barrier layer and the
barrier layer is situated
intermediate said base web and said nonwoven layer.
[0014] Some embodiments include a protective drainage wrap including a base
web having a
cross-woven or cross-laminate tape elements including first tape elements
extending in a.
drainage direction and second tape elements extending in a direction
transverse to the drainage
direction. The base web presents a front surface and a back surface
respectively defining a
front and back of the web. .A plurality of spaced apart, elongated drainage
yarns are supported
on a trout side of the base web and extending in the drainage direction. At
least some of the
second tape elements have a 3-13 topographic front surface with ridges and
channels extending
in the drainage direction.
100151 Some embodiments include a wrap that includes a base web including
cross-woven or
cross-laminate tape elements including first tape elements extending in a
drainage direction
and second tape elements extending in a direction transverse to the drainage
direction. The
base web presents a front surface of the base web and a back surface of the
base web. A
plurality of spaced apart, elongated drainage yams are situated adjacent the
from surface and
extending in the drainage direction. A 3-D topographic front layer is situated
over the base
web and drainage yarns. The front layer have a laterally directed undulating
front surface
characterized by ridges and channels in the drainage direction.
1001.61 Some embodiments include a protective drainage wrap that includes a
base web having
cross-woven or cross-laminate tape elements including first tape elements
extending in a.
drainage direction and second tape elements extending in a direction that is
transverse to the
drainage direction. 'The base web presents a back surface and a front surface.
A vapor-
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permeable and liquid iinpuneable barrier layer is situated adjacent the back
surface of the base
web, wherein the barrier layer is a non-porous monolithic film that is
permeable to water
molecules via molecular diffusion,
100171 Some embodiments include a protective drainage wrap for placement
intermediate a
protected structure and an external environ.ment. A frontward direction and a
backward
direct on respectively corresponds to a direction toward the external
environment and an
opposite direction toward the structure. The wrap includes a base web
comprising cross-woven
or cross-laminate tape elements including first tape elements extending in a
drainage direction
and second tape elements extending in a direction transverse to the drainage
direction. The base
web presents a front surface of the web and a back surface of the base web. A
plurality of
spaced apart, elongated drainage yarns are supported adjacent the front
surface of the base web
and extending in the drainage direction. At least some of said tape elements
are hydrophilic
tape elements .
[0018] In one aspect, the present disclosure presents a protective drainage
wrap including a
cross-woven base layer or fabric with a preferably breathable solid layer
portion and
characterized by enhanced drainage functionality. In one embodiment, the
barrier protection
system is equipped with oriented drainage channels and the system utilizes
capillarity-driven
flow elements in addition to gravity-driven flow mechanisms in the traditional
drainage
regions. In one variation, the capillarity-driven drainage elements are
elongated elements such
as cords or yams preferably made of hydrophilic, multilobal shaped fibers to
accommodate
higher fluid flows and compression resistance for maintaining overall drainage
volume in the
system. Furthermore, appropriate surface wettabilities may be provided to
create paths to feed
the wicking yarns.
[0019] In another aspect, the present disclosure presents a barrier protection
system, including
a protective drainage wrap, having a three-dimensional structure, either one
or two-sided. In
preferred embodiments, three-dimensional features or characteristics of the
system provides
for and maintains the desired drainage volume. The three-dimensional features
also provide
volume that contributes to evaporative drying due to air circulation. Further,
in these
embodiments, the desired three-dimensional features are created by the yam
and/or by surface
topography, introduced by such mechanism as embossing or creping, for example.
100201 In another aspect, a material barrier construction is provided
including a base web
equipped with a drainage surface and, further, drainage channels for quickly
passing water and
moisture downward from the system and from building surfaces, inducing
primarily by gravity-
driven flow. In a further aspect, the material barrier construction is
provided with elongated
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hydrophilic capillarity-driven flow elements that act as conduits for passing
water or moisture
drawn into the element. In a further aspect, the capillarity-driven flow
elements are
incorporated into and made a part of a cross-woven base web of the wrap, and
at least partly
defines the cross-section of the base web and the drainage surfaces of the
system, while also
presenting a conduit for capillary-driven and/or gravity-driven flow to add to
and assist
drainage capabilities. The present disclosure further provides material
selection and structural
options (e.g., modifications) to enhance the capillarity-driven flow elements
drainage
functionality (e.g., the wicking mechanism and capillary flow mechanism
inherent in the
structure).
[0021] In another aspect, a protective drainage wrap is provided having a
multi-laminate
structure (preferably tri-laminate). In one variation, the barrier protection
system incorporates
a top layer of sheet with a topography of appropriately oriented drainage
channels. The full
sheet may be creped or embossed spunbond, nonwoven or film.
[0022] In another aspect, a material barrier construction is disclosed having
a first portion
including a cross-woven base web or cross-laminate material, a coating making
up a second
portion or base layer. Preferably, the coating includes a polyolefin,
polyester, nylon or
combinations thereof, and the first and second portions are disposed adjacent
each other. In
specific embodiments, the base web is made up of a network of a first material
and a second
material. The first material can have a first thickness and be oriented in the
machine (i.e.,
relative to and transverse to a downstream or direction of drainage (or
vertical) when installed)
including a polyolefin, polyester, nylon or combinations thereof, the machine
direction
material. Preferably, the material in the other direction (cross-machine,
transverse or direction
of drainage) includes a polyolefin, polyester, nylon or combinations thereof,
and is
characterized by a second thickness. In a further aspect, the second thickness
is at least two
times greater than the first thickness so as to assist in providing drainage
for moisture build-
up. The present disclosure provides various improvements to this basic design,
including in the
selection of materials for system components, geometry and topography, and
modification to
material surfaces.
[0023] So that the manner in which the features and advantages of the systems,
apparatus,
products, and/or methods so of the present disclosure may be understood in
more detail, a more
particular description briefly summarized above may be had by reference to
specific
implementations of the barrier protection systems, apparatus, methods, and
products that are
illustrated in (some of) the appended drawings. It is to be noted, however,
that the drawings
illustrate specific implementations for illustration and are, therefore, not
to be considered
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limiting of the disclosed concepts as it may include other, effective
applications as well. It is
noted, in particular, that the exemplary applications described herein relate
to certain cross-
woven barrier protection systems and methods, employing specific components
and
component arrangements described as protective drainage wraps. These specific
constructions
and more detailed variations thereof are not limiting of the concepts. The
concepts described
herein can be used with most known building constructions and building
materials. Certain
applications may employ less than all of the various aspects described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] So that the manner in which the features of the compositions, articles,
systems and
methods of the present disclosure may be understood in more detail, a more
particular
description briefly summarized above may be had by reference to the
embodiments thereof
which are illustrated in the appended drawings that form a part of this
specification. It is to be
noted, however, that the drawings illustrate only various exemplary
embodiments and are
therefore not to be considered limiting of the disclosed concepts as it may
include other
effective embodiments as well.
[0025] FIG. 1A is a simplified, plan view illustration of a barrier protection
system and
apparatus, or protective drainage wrap;
[0026] FIG. 1B is a cross-sectional view of the protective drainage wrap of
FIG. 1A;
[0027] FIG. IC is a simplified, plan view illustration of a barrier protection
system and
apparatus, or protective drainage wrap;
[0028] FIGS. 2A and 2B are cross-sectional views of protective drainage wraps
installed on a
building in accordance with embodiments of the present disclosure;
[0029] FIG. 3A is a simplified illustration, in plan view, of a protective
drainage wrap
incorporating an embossed cross-woven base web or fabric and optional
interlaced, spaced-
apart hydrophilic elongated capillary-driven drainage elements, in accordance
with
embodiments of the present disclosure;
[0030] FIGS. 3B and 3C are cross-sectional views of two alternative
constructions of the
protective drainage wrap of FIG. 3A in accordance with embodiments of the
present disclosure;
100311 FIG. 3D is an elevation view (I) and micro cross-sectional views (II.
III, and IV) of
hydrophilic capillary-driven drainage elements or conduits or fibers, in
accordance with
embodiments of the present disclosure;
[0032] FIG. 4A is a simplified illustration, in plan view, of another
protective drainage wrap
incorporating a cross-woven base web or fabric and optional interlaced spaced-
apart
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hydrophilic capillary-driven drainage elements supported on hydrophilic cross-
directional
tape, in accordance with embodiments of the present disclosure;
[0033] FIGS. 4B and 4C are cross-sectional views of two alternative
constructions of the
protective drainage wrap of FIG. 4A in accordance with embodiments of the
present disclosure;
[0034] FIG. 5A is a simplified illustration, in plan view, of another
protective drainage wrap
incorporating a cross-woven base web or fabric featuring hydrophilic cross-
directional tape
elements and optional interlaced spaced-apart hydrophilic capillary-driven
drainage elements
supported on hydrophilic cross-directional tape adjacent additional
hydrophilic cross-
directional tape, in accordance with embodiments of the present disclosure;
[0035] FIGS. 5B and 5C are cross-sectional views of two alternative
constructions of the
protective drainage wrap of FIG. 5A in accordance with embodiments of the
present disclosure;
[0036] FIG. CA is a simplified illustration, in plan view, of another
protective drainage wrap
incorporating an embossed cross-woven base web or fabric featuring hydrophilic
cross-
directional tape elements and optional interlaced spaced-apart hydrophilic
capillary-driven
drainage elements positioned within troughs formed by embossing, in accordance
with
embodiments of the present disclosure;
[0037] FIGS. 6B and 6C are cross-sectional views of two alternative
constructions of the
protective drainage wrap of FIG. 6A in accordance with embodiments of the
present disclosure;
[0038] FIG. 7A is a simplified illustration, in plan view, of another
protective drainage wrap
incorporating a cross-woven base web or fabric featuring hydrophilic cross-
directional tape
elements and optional interlaced spaced-apart hydrophilic capillary-driven
drainage elements
supported on hydrophilic cross-directional tape and positioned within troughs
formed by
embossing, in accordance with embodiments of the present disclosure;
[0039] FIGS. 7B and 7C are cross-sectional views of two alternative
constructions of the
protective drainage wrap of FIG. 7A in accordance with embodiments of the
present disclosure;
100401 FIG. 8A is a simplified illustration, in plan view, of another
protective drainage wrap
incorporating a cross-woven base web or fabric featuring creped machine
direction tape
elements and optional interlaced spaced-apart hydrophilic capillary-driven
drainage elements,
in accordance with embodiments of the present disclosure;
100411 FIGS. 8B-8E are various cross-sectional views including alternative
constructions of
the protective drainage wrap of FIG. 8A in accordance with embodiments of the
present
disclosure;
[0042] FIGS. 9A-9C are cross-sectional views of a tri-layer laminate
protective drainage wrap
incorporating a cross-woven base web or fabric and an optional top layer
featuring a desired
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three-dimensional topography and a nonwoven bottom layer, in accordance with
embodiments
of the present disclosure;
[0043] FIG. 10A is a simplified illustration, in plan view, of an alternate
protective drainage
wrap incorporating a cross-woven base web or fabric featuring alternating
arrangement of
hydrophilic and hydrophobic machined-direction tape elements, in accordance
with
embodiments of the present disclosure;
[0044] FIG. 10B is a cross-sectional view of the protective drainage wrap of
FIG. 10A in
accordance with embodiments of the present disclosure;
[0045] FIG. 11 is a flow chart of a method of making a protective drainage
wrap in accordance
with embodiments of the present disclosure;
[0046] FIG. 12 is a flow chart of a method of installing a protective drainage
wrap in
accordance with embodiments of the present disclosure;
100471 FIG. 13 is a schematic of a system for making a protective drainage
wrap in accordance
with embodiments of the present disclosure; and
[0048] FIG. 14 is a simplified schematic of an installation of a wrap in
accordance with
embodiments of the present disclosure.
DETAILED DESCRIPTION
[0049] The present disclosure includes, generally, protective material barrier
constructions
and/or systems and apparatus for providing material barrier protection
relative to an adjacent
surface, as well as corresponding methods of barrier protection, installation,
and manufacture.
The present disclosure includes, more specifically, such systems, apparatus,
products, and/or
methods of barrier protection in respect of or for building surfaces against
weather or
environmental or other elements. The present disclosure includes systems of
material barrier
protection, which may include various components, including traditional
construction
components and building materials such as coatings, sheathing, panels, frame
elements and the
like, as well as specific components, layers, surface treatments and materials
for use with other
conventional or traditional building materials and constructions.
[0050] The protective drainage wraps, sometimes referred to herein as a -
system" or a
"construction- or "wrap-, whether single-layered or multi-layered, optionally
present extended
and substantially continuous surfaces, measurable by area and thickness. The
protective
drainage wraps are flexible, such that the wraps can be applied upon target
surfaces or spaces
between surfaces of various shapes and sizes. Embodiments of the wraps can be
applied over
an extended surface area and into and about different, but connected, areas
and contours. In
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this respect, systems and constructions disclosed herein are described, in
terms of application
or installations, as wraps or as being wrapped, particularly about or adjacent
the external
boundaries of a building. The use of such terminology as "wrap," "wrapping,"
and "wrapped"
is not meant, however, to impart structural limitations on the type or class
of construction
material disclosed or on the method of application of the various systems and
constructions
described herein.
[0051] The protective drainage wraps disclosed herein are generally employed
as secondary
weather barriers installed, during building construction, behind exterior
coverings such as
siding. In some embodiments, for optimal effect, the wraps or wrap components
or materials
are designed or installed to be both water resistant and water vapor
permeable. That is, the
wraps can be designed to prevent water penetrating the external building
coverings (e.g.,
siding) from intruding upon the covered internal layers; thereby, presenting a
solid barrier that
is aided by structural and/or material features exhibiting, enhancing, or
effecting desirable
drainage capabilities and evaporative effects.
[0052] The present disclosure is related to the subject matter disclosed in
ITS. Patent Nos.
6,550,212; 6,761,006; 6,869,901; 7,196,024; 8,334,223; 9,656,445; and
9,855,728, and, in
certain respects, to modifications, alternatives, enhancements, and/or
improvements to the
systems, products, processes, techniques, and methodologies disclosed in these
aforementioned
patents. Accordingly, descriptions and illustrations, as well as claims and
inventions provided
in these aforementioned patents may serve well as background and further
support for some of
the concepts presented in the present disclosure, including certain technical
problems addressed
by these concepts. Thus, the present disclosure may be read in view of, and
with reference to,
these aforementioned patents for at least the purpose of facilitating
understanding of the full
scope and extent of the present disclosure. Specifically, descriptions of
certain components or
materials or techniques that are suitable for use with embodiments of the
concepts introduced
herein, including descriptions of yarns and cord elements, tape materials, and
breathable
coatings may be applicable to some embodiments disclosed herein. The entirety
of these
aforementioned patents are, therefore, incorporated herein and hereto, and
made a part of the
present disclosure. The protective wraps described in these aforementioned
patents, most if
not all of which are commonly owned or controlled with the assignee of the
present application,
are material layered systems and products used in building constructions to
protect surfaces
against air infiltration and moisture build -up. These systems may be weath er-
res sti ve barriers,
which can also provide drainage functionality (hence, "protective drainage
wraps'). As with
previously-described systems and products (in the aforementioned patents), .tl-
te material barrier
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systems of the piesent disclosure are intended for, and applied, installed, or
inserted as layered
materials or constructions intermediate an external siding or layer of the
building construction
and an internal structural component or layer, such as wood paneling. The
wraps disclosed
herein may be protective wraps, drainage wraps, or weather-resistant wraps. In
some
embodiments the exterior of the protective drainage wraps disclosed herein do
not trap water
but, rather, allow and facilitate the flow or movement of water downward along
the wrap such
that the water exits the wall system. For purposes of the present description
of exemplary
applications, reference is made specifically to the use of yarns as capillary-
driven drainage
elements, but, its noted that other hydrophilic, elongated elements with
sufficient structural
integrity and capillarity and the above features and characteristics may be
used, to different
degrees of effect. See "Capillary Flow of Liquid Water through Yams: A
Theoretical Model",
by Hend Almoughni and Hugh Gong, Textile Research Journal published online 22
October
2014, http://trj.sagepub.com/content/early/2014/10/22/0040517514555797, which
is
incorporated herein by reference for background and made a part of the present
disclosure.
Protective Wraps
[0053] FIGS. 1A-1C depict barrier protection systems (i.e., protective
drainage wraps) in
accordance with those described in the aforementioned and incorporated
patents, including
U.S. Pat. No. 6,550,212. The depictions in FIGS. 1A-1C are included herein to
facilitate the
descriptions of the concepts introduced herein. Conventions and terminology
previously used
may be helpful, as well as reference made to the prior structures depicted,
when considering
the improvements and enhancements introduced herein. As will be evident,
understanding of
these improvements and enhancements, and of the various aspects and concepts,
may be more
readily achieved with reference and comparison to one such prior, base design
of a protective
drainage wrap.
[0054] With reference to FIGS. 1A-1C, protective drainage wrap 100 includes a
cross-woven
base web or network of fabric, including a plurality of hydrophobic cross-
directional (CD)
tapes 102 extending in the cross-direction (cross-machine direction or
vertical or drainage
direction in the drawing). The protective drainage wrap 100 includes a
plurality of hydrophobic
machine-directional (MD) tapes 104 extending in the machine-direction
(horizontal or lateral
direction in the drawing). The CD tapes 102 are weaved (interlaced) with the
MD tapes 104
to produce a generally contiguous, cross-woven base web or fabric. The
protective drainage
wrap 100 includes a plurality of elongated hydrophilic yams 106 that are
spaced apart in the
MD-direction, interlaced by the MD tapes 104, and directed in the CD-
direction. The yams
106 are directed such that when installed on a wall, the yarns 106 extend
downward to provide
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capillary-driven drainage. With reference to FIG. 1B, the protective drainage
wrap 100
includes a barrier layer 108 (sometimes referred to as a base layer) disposed
beneath and
adjacent the cross-woven base web formed by the tapes 102 and 104. The barrier
layer 108
can be a breathable (i.e., air and vapor permeable), solid coating layer that
is configured to
prevent or resist the passage of liquid water while also exhibiting air and
water vapor
permeability. FIG. 1B also illustrates the spacing between the material
components and layers
of the protective drainage wrap 100 includes, including horizontal and
vertical gaps between
the yarns 106 and the CD tapes 102 on either side of the yarns 106. Reference
may be made
to the previously incorporated patents, including U.S. Pat. No. 6,550,212, to
obtain details on
the design, construction and functionalities of the depicted wraps of FIGS. 1A
and 1B,
including material selection and drainage features (e.g., of the channels and
the yarn).
[0055] FIGS. 1A-1C also show the relative thickness of the yarns 106 as
compared to the
thickness of the tapes 102 and 104 and the barrier layer 108. When the
protective drainage
wrap 100 is installed, and an external layer or building material is placed
adjacent and atop the
protective drainage wrap 100, the yarns 106 act as spacers or bumpers that
create or enhance a
vertical gap between the fabric and the external layers. The yarn 106, tapes
102 and 104, and
gap define a drainage channel which facilitates movement of water and moisture
by gravity
away from the building and building materials, as described in the
aforementioned incorporated
patents. FIG. 1C shows that the draining direction (i.e., the direction that
liquid drains via
gravity and/or capillarity), when installed on a structure, corresponds with
the cross-direction
of the protective drainage wraps described herein.
Enhanced Protective Wraps
[0056] In one aspect, the barrier protection systems of the present disclosure
include structural
and/or material selection options that enhance drainage functionality by
enhancing gravity-
driven flow through the drainage channels described above, as well as
capillary-driven flow
via hydrophilic elements or conduits (e.g, yarns) that are located in spaced-
apart relation
adjacent the drainage channels. Specifically, the system designs provide new
and/or enhanced
capillary flow channels provided by, for example, bundles of hydrophilic
fibers generally
aligned in parallel (e.g., yarns or cords or monofiliments). Such drainage or
flow mechanisms
enhance the gravity-driven flow through the drainage channels (which, notably,
is partly
created and maintained by the thickness of the capillary flow elements ¨ i.e.,
the elongated
hydrophilic yams or cords). As described in more detail below with reference
to FIG. 3D, flow
through the fiber bundles can be optimized by maximizing the internal volume
in the fiber
bundle and the compressional resistance of the fiber bundle (e.g., yarn)
through, for example,
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the use of yarn composed of multi-lobal cross-sectional fibers. While yarn is
disclosed as being
used to form the capillary-driven drainage elements, the present disclosure is
not limited to the
use of yarn. Other hydrophilic, elongated elements with sufficient structural
integrity and
capillarity can be used in place of the yarns depicted in the Figures
disclosed herein. The
capillary-driven drainage elements can be at least partially formed by fiber
bundles other than
yarn and/or by strips or cords of other material, such as strips of low-
density nonwoven that
can be cross-laminated to a base web (weave of MD and CD tapes).
[0057] FIGS. 3A-14 provide illustrations of several variations and exemplary
applications
and/or embodiments of the barrier protection systems, apparatus, products, and
methods
according to the present disclosure, with particular focus on variations of
systems and apparatus
incorporating multiple functional layers or components including a cross-woven
base web or
fabric of interlaced elements (e.g., tapes) and, optionally, additional
functional components or
elements that are attached, integrated, or otherwise disposed adjacent and in
functional relation
with the cross-woven base web or fabric. In accordance with the present
disclosure, FIGS. 3A-
14 illustrate variations in the arrangement of these system elements as well
as variations in
each of the system elements. These variations and described features may
generally be regarded
as optional such that exemplary applications extend to systems, not depicted
or described
herein, that employ one or more of the features described, within the spirit
of the concepts and
aspects of the present disclosure. Additionally, one or more of the features
described in FIGS.
3A-14 can be combined together to provide for synergistic enhancement of the
properties of
the protective drainage wraps disclosed herein.
Shaped Protective Wraps
[0058] FIGS. 3A-3C illustrate a barrier protection system and apparatus
according to one
aspect of the present disclosure. The system and corresponding apparatus can
be positioned
internal of external members of building construction, such between siding,
and intermediate
of such external members and an internal member such as a framing member,
sheathing or
panel, which members require further coverage or protection from external,
environmental
elements (e.g., moisture). Thus, the systems disclosed herein can be
positioned between
sheathing and siding (e.g., bricks), for example. To facilitate further
description, the systems
disclosed herein are referred to as barrier protection systems or protective
drainage wraps,
noting that certain aspects described herein may present attributes or
improvements less
directed to drainage functionality than to other fun cti onaliti es. The
protective drainage wrap
reduces moisture penetration to the sheathing or framing members. Typically,
the protective
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drainage wrap is covered by an exterior covering such as siding, brick, stone,
masonry, stucco
(e.g., synthetic or cementitious) or concrete veneer.
[0059] FIG. 3A illustrates a protective drainage wrap 300 useful for attaching
to structural
members, such as sheathing or framing members. When installed, protective
drainage wrap
300 can be used to reduce moisture penetration to underlying sheathing or
framing members.
Typically, the protective drainage wrap 300 is covered by an exterior covering
such as siding.
The protective drainage wrap 300 includes hydrophobic MD tape 304, hydrophobic
CD tape
302, and hydrophilic yarn 306 weaved together to form a network or web. While
described as
including a weaved web or network, the protective drainage wrap is not limited
to a particular
form of fabric. The tapes 302 and 304 are woven together in a plain weave
style, such that the
MD tapes 304, also referred to as tapes, are oriented in the machine
direction, and such that the
CD tapes 302, which are also referred to as weft tapes, are oriented in the
cross direction, which
is generally orthogonal to the machine direction. When placed over structural
members, the
CD direction is generally a vertical direction relative to the structure
(i.e., the drainage
direction) and the MD direction is generally a horizontal direction relative
to the structure.
Throughout this disclosure, the terms -cross-directional" and -cross-
direction" and -CD" are
used to refer to the direction that is intended to be the direction of
drainage along the protective
drainage wrap or the direction, when installed, that drainage occurs. The
drainage direction
typically aligns with the direction of gravity, i.e., the liquid drains
downwards towards the
ground. Throughout this disclosure, the terms "machine-directional" and
"machine-direction"
and "MD" refers to a direction that is transverse to the CD. While "machine-
directional" and
"machine-direction" and "MD" may correspond with a machine or lateral
direction associated
with the manufacture of some embodiments of the protective drainage wrap, the
directions
disclosed herein are not limited by directionalities used during the
manufacturing process.
[0060] The tapes 302 and 304 are woven together in an over-and-under sequence
to form a
cross-woven base web. The cross-woven base web can have an equal number of CD
tapes and
MD tapes, more CD tapes than MD tapes, or less CD tapes than MD tapes. As used
herein,
the "cross-woven base web" refers to the weaved fabric formed by the woven
together CD
tapes 302 and MD tapes 304. As shown in FIGS. 3A-3C, the hydrophilic yarn 306
is weaved
with the CD and MD tapes 302 and 304 and, thus, incorporated into the cross-
woven base web.
The yarns 306 extend substantially in the CD direction and substantially
parallel with the CD
tapes 302. The yarns are positioned on top of at least some of the tapes. For
example, as shown
in FIGS. 3A-3C, the yarns 306 are positioned on top of one of the CD tapes
302, intermittently
on top of alternating MD tapes 304, and intermittently beneath alternating MD
tapes 304. Thus,
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the yarns 306 are structurally supported by the CD tapes 302 and the MD tapes
304 that are
positioned beneath the yarns 306, and are maintained in position within the
weave of the cross-
woven base web by the MD tapes 304 that extend over the yams 306.
[0061] The cross-woven base web formed by the weaved tapes 302 and 304 can be
or present
a solid continuous web or layer of material beneath the yam 306. As shown in
FIG. 3A, a CD
tape 302 and portions of alternating MD tapes 304 are positioned underneath
each yarn 306.
As such, along an entire cross-directional extent of each yam 306, a CD tape
302 (or a
combination of a CD tape 302 and an MD tape 304) is positioned between the yam
306 and
the underlying barrier layer 308. While described as a barrier "layer" the
barrier material is
not limited to a particular form and method of application. Thus, in some
embodiments the
yarns 306 are maintained spaced apart from the barrier layer 308 and are not
in contact with
the barrier layer 308. The solid web or layer of material provided by the
cross-woven base web
that is beneath the yarn 306 can act to protect the yam 306 from damage, such
as during
handling and installation. In embodiments where the CD tapes 302 positioned
directly
underneath the yarns 306 are hydrophobic, the CD tapes 302 reduce the
penetration of liquid
(also referred to as liquid breakthrough) through the cross-woven base web and
to the base
layer 308. Thus, the hydrophobic CD tapes 302 on which the yams 306 are
supported can
prevent water from penetrating through the protective drainage wrap 300 to the
barrier layer
308 on the backside of the protective drainage wrap 300.
[0062] The yams 306 can have hydrophilic properties that enable the yams 306
to wick
moisture. For example, water along the surface of the protective drainage wrap
300 can be
attracted to the yams 306 due to the hydrophilic properties of the yarns 306.
Water drawn into
the yarns 306 can travel downward through the length of yarns 306 along the CD
direction.
The downward travel of water through the yams 306 can be due, in part, to
gravity and, further,
in part to capillary-driven flow through the yams 306. Thus, the yams 306 can
function as
capillary-driven and gravity-driven drainage channels or conduits that
facilitate water drainage
downward and across the surface of tapes 302 and 304.
[0063] With the yams 306 positioned on top of the CD tapes 302, the yarns 306
can absorb
and wick away more liquid in comparison to a wrap in which no CD tape is
positioned beneath
and supporting the yarn along the CD extent of the yarn. For example, when the
yarn 306 is
saturated with a maximum amount of liquid therein, then the hydrophobic CD
tape 302
supporting the yarn 306 can maintain the position of water at or near the yam
306 until the yarn
306 is no longer saturated (after further wicking) and is able to absorb and
wick away additional
liquid from the CD tape 302.
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[0064] As illustrated, the yarns 306 are positioned on every fourth CD tape
302. However, the
wraps disclosed herein are not limited to this arrangement, and the yarns can
be placed at more
or less frequent intervals than is shown in the Figures. Additionally, the
yarns may be evenly
distributed with equal intervals between adjacent yarns (as shown) or the
yarns may be
distributed with unequal intervals.
[0065] The cross-woven base web formed of the weaved CD tape 302 and MD tape
304
provides tensile properties and high tear resistance to the protective
drainage wrap 300, while
the yarn 306 of the cross-woven base layer provides an integral drainage
structure that is
oriented downwards to direct water towards a bottom edge of the protective
drainage wrap 300
(e.g., towards the ground when installed).
[0066] FIGS. 3B and 3C depict alternative cross-sectional views of the
protective drainage
wrap 300 of FIG. 3A, along line A-A. As shown in FIGS. 3B and 3C, the CD tapes
302 and
yarn 306 of the protective drainage wrap 300 are supported on a breathable,
solid barrier layer
308, which can be in the form of a coating or film, for example. The barrier
layer 308 can
provide liquid water resistance (i.e., can be substantially impermeable to
liquid water) and
water vapor permeability (i.e., can be vapor permeable to air and water
vapor). FIG. 3B is a
simplified at least partially exploded view showing the barrier layer 308
spaced apart from the
base web; however, the barrier layer may be laminated directly onto the base
web.
[0067] In some embodiments, the barrier layer 308 is a microporous film layer.
The barrier
layer 308 can be a microporous polymer films, such as those constructed from
stretched polyolefins. For example, the barrier layer 308 can be an extruded
and biaxially
stretched CaCO3 filled polypropylene, stretched polytetrafluoroethylene
(PTFE), or
precipitation-cast polyurethane. Such microporous film layers are vapor
permeable via pores
through the film. The relatively small size of the pores in these microporous
films prevents the
penetration of liquid water, but the interconnected pore structure allows for
transmission of
water vapor, air, and other gases.
[0068] In some embodiments, the base layer 308 can be monolithic extruded
film. Such
monolithic extruded films lack pores (i.e., are non-porous) and are permeable
via molecular
diffusion. The monolithic extruded films can be hydrophilic. The monolithic
films present a
continuous surfaces that is free of pores. The monolithic extruded films are
impermeable to
liquid water, but allow passaged of molecular water via diffusion through the
film. Monolithic
breathable films can transmit water vapor through an absorption-diffusion
mechanism, such
that the film is capable of absorbing gas and water molecules on one surface,
transferring the
molecules through the film, and releasing the molecules on the opposite
surface. Examples of
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breathable monolithic films include thermoplastic elastomers (TPE), polar
copolymers, and
polyester elastomers such as Pebax an Lotrylk polymers. Compared to
microporous films,
monolithic films have an increased ability to prevent the passage of liquid
(i.e., act as a liquid
barrier). The liquid barrier properties of a monolithic film are independent
of the surface
tension of the liquid to which the film is exposed. For example, the liquid
barrier properties of
a monolithic film are not substantially affected by the introduction of a
surfactant (e.g., where
water on the wrap has surfactant therein), which can cause the surface of the
film to exhibit
hy. drophi li city.
[0069] In some embodiments, the barrier layer is a monolithic extruded film
that is a smart
vapor retarder that exhibits water vapor permeability that variable with
relative humidity, such
as a polyamide (nylon) or vinyl alcohol copolymer (EVOH, PVOH). That is, the
smart vapor
retarder can have increased vapor permeability with increased ambient
humidity, and decreased
vapor permeability with decreased ambient humidity. Thus, in humid conditions,
the smart
vapor retarder can allow for water molecules to pass therethrough via
molecular diffusion
through the film. Such a film can retard vapor diffusion in less-humid
conditions, while
allowing vapor transmission and drying in more humid conditions. The smart
vapor retarder
can be hygroscopic, such that the film absorbs water when exposed to ambient
humidity. Water
molecules can lodge between the molecules of the film, which can act as valves
on a molecular
scale, allowing water vapor to travel through the film. Some exemplary smart
vapor retarders
are manufactured by Arkema (https://hpp.arkema.com/en/markets-and-
applications/chemical-
industry-and-general-industry/breathable-films/) and Pebax Thermoplastic
elastomers
(https://www.mddionline. com/packaging/breathable-tpe-films-medical-
applications).
[0070] In FIG. 3B, the protective drainage wrap 300 is shaped such that
channels 310 are
formed on a front side of the protective drainage wrap 300. With reference to
FIGS. 2A and
2B, as used herein the -front" or "frontside" refers to the side or surface of
the protective
drainage wrap that faces the siding and environment exterior to a structure
when installed in
the structure, and the "back" or "backside" refers to the side or surface of
the protective
drainage wrap that faces the sheathing and interior of the structure when
installed in the
structure. Additionally, describing a first element as being -frontward" of a
second element
indicates that the first element is positioned closer to the front of the
protective drainage wrap
and siding and exterior environment than the second element. Also, describing
a first element
as being "backward" of a second element indicates that the first element is
positioned closer to
the back of the protective drainage wrap and sheathing and structure than the
second element.
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[0071] In some embodiments, the shaping of the protective drainage wraps
disclosed herein is
achieved via embossing one or more material elements of the protective
drainage wraps. For
example, the CD tapes, the MD tapes, the base layer, or some combination
thereof can be
shaped (e.g., embossed). The channels 310 (or troughs) extend generally in the
CD direction
and generally parallel with the CD tapes 302. The channels 310 provide a path
along which
gravity-driven fluid can flow within the protective drainage wrap 300. As
illustrated, every
fourth CD tape 302 is embossed to form a channel 310. However, any number of
the CD tapes
302 can include an embossed channel, and the channels can be evenly spaced (as
shown) or
unevenly spaced. While not shown, in some embodiments, at least some of the MD
tapes can
be embossed to form channels. The channels 310 are intermediate the yams 306.
However, in
some embodiments, the channels can be coincident with the yarns, or both
intermediate of and
coincident with the yarns. While not shown in the cross-directional views of
FIGS. 3B and 3C,
at some MD cross-sections, the MD tape weaves over the yarn 306.
[0072] The channels 310 can increase the volume of liquid that can be drained
by the protective
drainage wrap 300. In some embodiments, the channels 310 provide a passage for
air flow to
increase the amount of air drying of liquid on the protective drainage wrap
300. Air drying can
be useful for drying liquid that does not accumulate sufficiently to flow.
Embossed channels
in the MD direction can increase the flow of liquid across the protective
drainage wrap to the
channels that extend in the CD direction and/or to the yams. The embossing can
be performed
before or after the CD and MD tapes are woven together, and before or after
the base layer is
coupled with the cross-woven base web. In embodiments where the CD tapes are
embossed
after being woven with the MD tapes, then at least some portion of the MD
tapes that overlap
the embossed CD tapes will also be embossed. FIG. 3C depicts an alternative
embodiment of
the protective drainage wrap that does not include embossed channels. For
example, for
reference see the cross-sectional view in FIG. 8C which shows a weave pattern
of a similar,
although not identical, MD tape 804.
[0073] The CD and MD -tapes disclosed herein can be made of the same or
different materials.
In some embodiments, all of the MD and CD tapes are made of a first material_
In other
embodiments, all of the CD tapes are made of a first material and all of the
MD tapes are made
of a second material that is differein than the first material. Additionally.
all the Cf.) tapes
disclosed herein can. he made of the same material, or the plurality of CD
tapes can include
multple different CD tapes made of different materials. Si 311 t arty , at t
the MD tapes disclosed
herein can be made of the same material, or the plurality of MD tapes can
include multiple
different MD tapes made of different materials.
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[0074] In some embodiments, the CD and MD tapes include a hydrophobic
material. In some
embodiments, the CD and MD tapes include a hydmphilic material. In sot .e
embodiments, the
CD and/or MD tapes include some tapes of a hydrophobic material and some tapes
of a
hydrophilic material. The CD and MD tapes can be polymeric, and can include
polyolefins,
polyesters, nylons, ethyle.,ne vinyl alcohol, or combinations thereof Some
exemplary
polyolefins that can be used in forming the CD and MD tapes include
polypropylene or
polyethylene.
[0075] The polypropylene can be a homopolymer or a polypropylene copolymer,
such as a
copolymer of propylene with other aliphatic polyolefins, such as ethylene, -
buterie,l-pentene,
3-me thy I-I- b u tene, 4-methyl- l -pen tene, 4-methy I-I -hexene, 5-methyl-I-
hexene, or mixt ures
thereof in some embodiments, the copolymers disclosed herein include at least
50 mole
percent of propylene units with the minor proportion, in mole percent,
including other
monomers that are copolymerizahle with propylene. In some embodiments, the
copolymers
disclosed herein include 50 percent by weight of propylene monomer units with
the minor
proportion, M weight percent, including other monomers that are
copolymerizable with
propy one
[0076] The polyethylene disclosed herein can be a hornopolymer or a copolymer.
Some
examples of polyethylene suitable for use herein are low density polyethylene
(1_,DPE), medium
density polyethylene (MDPE), high density polyethylene (I-IDPE), very low
density
polyethylene (VLDPE), linear low density polyethylene (II:DPE), and
inetallocerte-catalyzed
linear low density polyethylene (mLLDPE). The polyethylene can be a copolymer
of ethylene
with other aliphatic polyolefins.
100771 The polyesters disclosed herein can include a. polyester resin that is
a. polycondensation
product of a dicarboxylic acid with a dihydroxy alcohol. 'Me polymer disclosed
herein can be
or include a polyethylene terephthalate that includes a polyester resin made
from ethylene
glycol and terephthalic acid. The polymer disclosed herein can be or include a
nylon that is a
polyamide polymer characterized by the presence of an amide group __ CONH).
100781 Ethylene-vinyl alcohol (EVOH) is a thermoplastic copolymer of ethylene
and vinyl
alcohol. In commercial EVOII resins, the vinyl alcohol content typically
various between about
55 and 75 mole percent. EVOII can function as a smart vapor retarder due to
its property of
increased water vapor permearice with relative humidity.
100791 In some embodiments, the polymer of the CD and MD tapes disclosed
herein can
include melt additives. In some embodiments, the polymer of the CD and MD
tapes is or
includes a smart vapor retarder film, such as when the tape is a hydrophilic
tape. In some
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embodiments, the polymers of the CD and MD tapes are copolymers that are
configured to
have a desired wettability and hydrophilicity.
Shaped Fibers
100801 In some embodiments, the yams disclosed herein a made of fibers that
have a cross-
sectional shape or profile that is configured to provide capillary voids
between the fibers,
configured to provide compressive strength to the yarn, or combinations
thereof. For example,
the fibers can be shaped such that the fibers have a non-circular cross-
section. Such fibers with
a non-circular cross-section can include one or more protrusions that extend
outward from a
center of the fiber in some embodiments, the fibers with a non-circular cross-
section are
muhilobal, such as bilobal, trilobal, tetra-Jo-bat, quadralobal, pernaiuba1,
hexa-lobal,
hectalobal, or octolobal. The cross-sections of such multilobai fibers include
multiple separate
lobed portions that extending from a. centrally located portion of the fiber.
When such non
circular cross-sectional fibers are packed together in a yam, void spaces
exits between the fibers
that serve as capillary tubes or pores within the yam. Thus, the shaped fibers
can increase the
capillarity of the yarns and increase the bulkiness oldie yam_ Additionally,
fibers with a non
-
circular cross-section have more surface area in comparison to an otherwise
identical fi her that
has a circular cross-section. The additional surface area of' the fibers
increases the ability of
the fibers to wick and transport (via capillary action) more liquid. The
surface areas of fibers
with a non-circular cross-section, relative to an otherwise equivalent
circular fiher is higher
and increases with the number of lobes. The surface area increase of the
fibers with a non
circular cross-section can be estimated from the ratio of fiber perimeter of
the shaped fiber
relative to the perimeter of an otherwise equivalent fiber with a circular
cross-section. For
example, the surface area of the fibers with a non-circular cross-section can
be from 1.1 to 3 or
1..3 to 1.7 limes greater than an otherwise equivalent fiber with a circular
cross-section The,
increase in surface area is not limited to these exemplary ranges, and can be
more or less
depending on the particular fiber.
100811] Yarns of fibers with a non-circular cross-section have increase
compressive strength
relative to otherwise identical yarns of fibers with circular cross-sections_
The fibers disclosed
herein can be synthetic polymer fibers made by extrusion of a molten polymer
from a die that
is shaped to provide the fibers with the desired non-circular cross-section.
The fibers can be
continuous fibers or subs.tan Li ally continuous along the extent of the yarn.
100821 Thus, the fibers have a non-circular shaped cross section that
maximizes the pore
volume of the yarn, and maximizes the bulk and compressive resistance of the
yam. The higher
pore volume of the yarn provides for increased drainage of liquid through the
yarn. The higher
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bulk of the fibers provides for larger fiber protrusions, resulting in more
air volume in the yarn
for increased drainage and air drying. The higher compressive resistance of
the yam and fibers
allows the yarn and fibers to avoid compression and, thereby, persevere the
increased space
and pore volume.
[00831 The rnultilobal fibers have individual wicking channels that increase
with number of
lobes. When bundled Uri a yarn structure, some advantages provided by
multilobal fibers
include higher inter-fiber pore volume and bulk and compressional resistance,
which provides
increased liquid transport for enhanced drainage and enhances the ability of
the yam to act as
a spacer when the protective drainage wrap is installed on a structure.
100841 In some einbodiments, the yarn thickness (denier) is selected to
provide a desired
protrusion height of the yam from the frontside of the cross-woven base web.
For example,
the yarn can have a thickness (denier) ranging from. 0.7 mm to 4 mm, or from
.1 to 3, or
preferably 2 mm.
[008.5] FIG 3D(I) depicts a yam 306 and two alternative cross-sectional views
(II and Ill) of
a yarn showing the cross section of fibers of the yarn 306_ The yarn 306 can
be a hydrophilic
yarn that provides an elongated capillary-driven conduit for water in the
protective drainage
wraps disclosed herein. The yarn 306 can be made of a plurality of continuous
fibers 312 or
314 having cross-sections that are shaped to provide desired properties (e.g.,
capillarity and
compressive strength). Suitable fibers 312 are octolobal, and suitable fibers
314 are trilobal. In
a yarn of such multi-lobal fibers, interstitial space 316 is positioned
between adjacent
fibers. The interstitial space 316 between the fibers forms channels, tubes or
pores that induce
and/or facilitate capillary-driven and/or gravity-driven fluid flow downwardly
(drainage
direction) through the yarn to a lower edge of the protective drainage wrap
and away from the
underlying building surfaces. In addition, the fibers 312 or 314 of the yarn
306 can be made
of a material that is hydrophilic. FIG. 3D (W) shows a collection of other
exemplary fibers
having a non-circular cross section, including fiber 360 having an oval or
ovoid cross-section,
fiber 362 having a quadrilobal cross-section, and fiber 364 having a
pentalobal cross-
section. The yarns disclosed herein are not limited to fibers with these
particular cross-
sections, and can include other multi-lobal fibers or other fibers having a
non-circular cross-
sections. The fibers having a non-circular cross-sections can have regular,
symmetrical cross-
sections, or irregular, asymmetrical cross-sections.
[0086] In some embodiments, the cross-section of the fibers have an aspect
ratio that is not
1:1, such as an aspect ratio of greater than 1:5. In some embodiments, the
cross-section of the
fibers having a non-circular cross-section has a shape factor of greater than
1. As would be
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understood by one skilled in the art, the shape factor is the ratio of the
perimeter of the cross-
section of the non-circular fiber to the circumference of the equivalent area
of an otherwise
identical fiber having a circular cross-section.
Protective Wraps with Hydrophilic CD Tape
[0087] In some embodiments, one or more of the tapes of the protective
drainage wraps can be
hydrophilic. With reference to the protective drainage wrap 400 of FIGS. 4A-
4C, a first portion
of the CD tapes 402a are hydrophobic and a second portion of the CD tapes 402b
are
hydrophilic. In particular, the CD tapes 402b that are positioned beneath the
yams 406 are
hydrophilic, with the remaining CD tapes 402a and the MD tapes 404 being
hydrophobic.
Positioning hydrophilic CD tapes 402b beneath the yarns 406 can increase the
amount of water
on the web of the protective drainage wrap 400 that is drawn to the yam 406;
thereby,
increasing the amount of water the yarn 406 is able to wick away from the
remainder of the
web of the protective drainage wrap 400. The hydrophilic CD tape 402b can act
as a funnel
that directs or draws liquid to the yarn 406. In some embodiments, the yarn
406 is more
hydrophilic than the hydrophilic CD tape 402b such that liquid more readily
flows from the
hydrophilic CD tape 402b to the yarn 406. The CD tape 402b supporting the yarn
406 can
facilitate the preservation of the structural integrity of the underlying
barrier layer 408 and
reduce the probability of liquid water intrusion there-through.
[0088] As shown in FIG. 4B the protective drainage wrap 400 can be shaped
(e.g., embossed)
to form channels 410 as described above in reference to FIG. 3B.
Alternatively, embodiments
of the protective drainage wrap 400 may not be embossed, as shown in FIG. 4C.
In some
embodiments, the embossed tape that forms the channels 410 is hydrophobic, as
a hydrophobic
surface facilitates the formation and maintenance of water in the form of
droplets for the
purposes of drainage and air drying. The droplet shape of the water in the
channels 410 can,
in turn, cause the water to flow more readily on the surface of the channels
410. The channels
410 can be positioned in areas where the yarn 406 is not positioned to wick
away moisture,
such as in the gaps between the yams 406. Thus, the embodiment of FIGS. 4A and
4B
combines the use of hydrophilic CD tape 402b at, under, or near the yam 406
with the use of
hydrophobic CD tape 402a in areas that are not under the yam 406; thereby,
increasing water
drainage properties of the protective drainage wrap 400. As shown in FIGS. 4B
and 4C,
respectively, the barrier layer 408 can be embossed or not embossed. FIG. 4B
is a simplified
at least partially exploded view showing the barrier layer 408 spaced apart
from the base web;
however, the barrier layer may be laminated directly onto the base web.
Gradient Hydrophilicity
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[0089] In some embodiments, the CD tapes both beneath and adjacent the yarn
are hydrophilic.
With reference to FIGS. 5A-5C, protective drainage wrap 500 includes a first
portion of the
CD tapes 502a that are hydrophobic, a second portion of the CD tapes 402b that
are hydrophilic
and positioned beneath the yam 506, and a third portion of CD tapes 402c that
are hydrophilic
and positioned adjacent the CD tapes 402b and adjacent the yams 506 (i.e.,
between the CD
tapes 402a and 402b. The MD tapes 504 in this embodiment are hydrophobic.
[0090] The additional hydrophilic CD tapes 502c (relative to the embodiment
shown in FIG.
4A) can attract additional liquid to and adjacent the CD tapes 502b and,
thereby, the yam 506,
where the liquid can then be wicked away by the yarn 506. The use of
additional hydrophilic
CD tapes 502c can increase the surface area that attracts liquid to the yarn
506. In some
embodiments, the level of hydrophilicity can be varied between the various CD
tapes 502b and
502c and the yarn 506. For example, the CD tape 502b, beneath the yam 506, can
be more
hydrophilic than the CD tape 502c adjacent the yam 506, and the yarn 506 can
be more
hydrophilic than the CD tape 502b. In such a configuration, the liquid can be
encouraged to
flow from the less hydrophilic CD tape 502c to the more hydrophilic CD tape
502b, and then
to the yarn 506. In the embodiment depicted in FIG. 5B, the CD tape 502a that
is embossed to
form channels 510 is hydrophobic to maintain flow of liquid along the surface
of the channels
510. The barrier layer 508 can be embossed as shown in FIG. 5B, or not
embossed as shown
in FIG. 5C. FIG. 5B is a simplified at least partially exploded view showing
the barrier layer
508 spaced apart from the base web: however, the barrier layer may be
laminated directly onto
the base web.
Hydrophilic Yarns Positioned in Embossed Channels
[0091] In some embodiments, the CD tape that is positioned beneath the yarn is
shaped (e.g.,
embossed) to have a channel or trough and the yarn is positioned within the
channel. With
reference to FIGS. 6A-6C, protective drainage wrap 600 is embossed to form
channels 610a
and 610b. The yams 606 are positioned within the channels 610b, and the
channels 610a are
empty (i.e., do not have yarn positioned therein). The CD tape 602b that forms
the channels
610b is hydrophilic, and the remaining CD tape 602a, including the CD tape
that forms the
channels 610a, is hydrophobic. The embossed shape of the CD tape 602b provides
a flow path
of liquid toward the yarn 606 that is based on the shape of the yarn. The
embossed CD tape
beneath the yarn can be hydrophilic or hydrophobic, as the shape of the
embossed tape is used
to draw liquid toward the yarn, regardless of whether the embossed tape is
hydrophilic or
hydrophobic. As with the prior described embodiments, the MD tape 604 is
hydrophobic, and
the barrier layer 608 is a breathable, solid coating layer that is embossed.
FIG. 6C is an
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alternative embodiment that includes only the channels 610b, and does not
include the channels
610a between the yarn 606. FIGS. 6B and 6C are simplified at least partially
exploded views
showing the barrier layer 608 spaced apart from the base web; however, the
barrier layer may
be laminated directly onto the base web.
[0092] FIGS. 7A-7C depict an embodiment similar to FIGS. 5A-5C, but with the
addition of
the yarn being positioned in, on, or within embossed channels. Protective
drainage wrap 700
includes a first portion of the CD tapes 702a that are hydrophobic, a second
portion of the CD
tapes 702b that are hydrophilic and positioned beneath the yarn 706, and a
third portion of CD
tapes 702c that are hydrophilic and positioned adjacent the CD tapes 702b and
adjacent the
yarns 706. The MD tapes 704 are hydrophobic. The protective drainage wrap 700
is embossed
to form channels 710a and 710b. The yarns 706 can be positioned within the
channels 710b,
and the channels 710a can be empty. The CD tape 702b that forms the channels
710b is
hydrophilic, the CD tape 702c that adjacent the channels 710b are hydrophilic,
and the CD tape
702a form the channels 710a are hydrophobic. As with the prior described
embodiments, the
MD tape 704 can be hydrophobic, and the breathable, solid coating layer 708
can be embossed.
FIG. 7C is an alternative embodiment that includes only the channels 710b, and
does not
include the channels 710a between the yarn 706. FIGS. 7B and 7C are simplified
at least
partially exploded views showing the barrier layer 708 spaced apart from the
base web;
however, the barrier layer may be laminated directly onto the base web.
Materials with a Three-Dimensional Topography
[0093] In some embodiments, one or more of the materials of the protective
drainage wraps
have a three-dimensional topography that is configured to increase the surface
area of the
material, promote gravity-driven drainage, promote air drying, or combinations
thereof The
three-dimensional topography can be achieved via embossing as described above
or creping,
for example. For example, the MD tapes and/or CD tapes can be shaped to have a
three-
dimensional topography.
[0094] FIGS. 8A-8C depict an embodiment of a protective drainage wrap with MD
tapes
having a three-dimensional topography (e.g., creped tapes). While shown as
creped tapes, the
three-dimensional topography is not limited to being in the form of creping.
The three-
dimensional topography can present an undulating surface with spaced apart
ridges and valleys.
The three-dimensional topography cam be formed by creping, folding, gouging,
or another
method. Protective drainage wrap 800 includes CD tapes 802 that are
hydrophobic, a first
portion of MD tapes 804a that are hydrophobic, and a second portion of MD
tapes 804b that
are hydrophobic and creped. The protective drainage wrap 800, including the
barrier layer 808,
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can be embossed to form channels 810 in the drainage direction as shown in
FIG. 8B, or not
embossed as shown in FIG. 8C. While the CD tapes 802 are hydrophobic, in some
embodiments the CD tapes are hydrophilic, and, preferably, the CD tapes 802
below the yarns
806 are hydrophilic.
[0095] The yarns 806 are positioned between the channels 810. As shown in FIG.
8A, the MD
tapes 804a are weaved above the yarns 806, and the MD tapes 804b are weaved
beneath the
yarns 806.
[0096] The creping of the MD tapes 804b provides a physical structure to the
MD tapes 804b
such that the surface of the MD tapes 804b includes a ridged or corrugated or
undulated profile
with ridges and valleys. The creping can include pushing together the surface
of a tape until
the tape buckles, forming the ridges and valleys. The ridges and valleys of
the MD tapes 804b
extend in a direction that is orthogonal to the direction that the MD tapes
804b extend. In FIG.
8A, the MD tapes 804b extend in the MD direction, and the ridges and valleys,
thus, extend in
the CD direction. As such, the MD tapes 804b provide channels (i.e., the
valleys) along which
liquid is encouraged to flow; thereby, increasing the fl ow rate of liquid
along the protective
drainage wrap 800.
[0097] The creping of the MD tapes 804b can also provide for the passage of
air to increase
the amount of air drying of liquid, such as for drying liquid that does not
accumulate
sufficiently to flow. The number of crepes per unit length and the depth
(i.e., the height
difference between adjacent ridges and valleys) of the creping can be adjusted
as desired. In
the embodiment shown in FIG. 8A, the MD tapes alternate between creped MD
tapes 804b and
MD tapes 804a that are not creped. However, the number and pattern of creping
can be varied.
The creped MD tapes 804b may be more subject to stretching and elongating
relative to the
MD tapes 804a that are not creped. In embodiments with both creped MD tapes
804b and MD
tapes 804a that are not creped, the creped MD tapes 804b provide the drainage
and air-drying
benefits described above and the MD tapes 804a that are not creped provide
tensile strength to
the cross-woven base web in the MD direction. Thus, the MD tapes 804a prevent
the stretching
and elongation in the MD direction that may occur if all of the MD directed
tapes were creped.
In some embodiments, the creped MD tapes 804b are creped tapes having a crepe
height that
is less than the thickness of the yarn, such as from about 1 to about 2 mm,
plus or minus 10%.
The creped MD tapes 804b can exhibit a percent of crepe of from 5 to 75%, or
10 to 65%, or
25-50%, or any range or discrete value therebetween.
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[0098] FIGS. 8B-8D are simplified at least partially exploded views showing
the barrier layer
808 spaced apart from the base web; however, the barrier layer may be
laminated directly onto
the base web.
Multi-Layer Construction with Three-Dimensional Topography
[0099] With reference to FIGS. 9A-9C, some embodiments include a barrier
protection system
that has a multi-component and/or multi-layered construction incorporating the
cross-woven
base web or fabric and a top layer, an additional barrier layer, or
combinations thereof
[00100]
FIG. 9A depicts an embodiment of protective drainage wrap 900 including a
barrier layer 908 that is a breathable, solid coating layer as a backing
beneath (i.e., on a
backside) of the cross-woven base web, CD tape 902 on the barrier layer 908
and embossed to
form channels 910, yarns 906 supported on hydrophobic CD tape 902, and a top
layer 920.
[00101]
The top layer 920 has a three-dimensional topography. In the embodiment of
FIG. 9A, top layer 920 is a creped fabric, such as a creped spunbond or creped
film or embossed
spunbond. The creped top layer 920 has channels 922 that are directed in the
CD direction that
provide increased drainage volume to promote enhanced drainage and provide
higher surface
area for enhanced air drying. In some embodiments, the creped top layer 920
provides thermal
insulative properties to the protective drainage wrap 900. Thus, the top layer
920 is provided
with a textured surface that imparts or exhibits a desired 3-D topography.
Embossed spunbond
or nonwoven can also achieve the desired 3-D topography, such as by employing
certain bond
patterns to create desired directional drainage surface tendencies. The 3-D
topography results
in increased surface area for the top layer 920 (with the same base web
footprint), as would be
evident if the 3-D surface were stretched and flattened to expose the extended
surface of the
facing layer. Such an increased surface area also provides an extended surface
for moisture to
collect or set; thereby, facilitating air drying. Additionally, the increased
thickness and space
created by the 3-D topography presents thermal insulative properties ¨
presenting both
increased air space and solid media as additional layers of insulation (i.e.,
heat transfer media).
In some embodiments, the top layer 920 is a creped film or spunbond having a
crepe height
that is less than the thickness of the yam 906, such as from about 1 to about
2 mm, plus or
minus 10%. The top layer 920 can exhibit a percent of crepe of from 5 to 75%,
or 10 to 65%,
or 25-50%, or any range or discrete value therebetween.
1001021
As shown in the cross-sectional views, the 3-D surface presents troughs 922
and
valleys directed in the CD direction, which function as drainage channels.
Even if the troughs
922 do not extend continuously and uninterrupted to the bottom edge of the
protective drainage
wrap 900, the surface can provide a concentration or collection of channels
and mini-channels
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that present a network of channels, collectively passing fluid flow in the CD
direction.
Additionally, the3-D topography of the creping provides for increased
thickness and space
[00103]
The protective drainage wrap 900 also includes MD tape (not shown). In the
embodiment of FIG. 9A, the yam 906 is positioned between the top layer 920 and
at least some
of the CD tapes 902. Thus, the embodiment shown in FIG. 9A is a tri-layer
laminate, including
a first layer that is the barrier layer 908, a second layer that is the cross-
woven base web formed
of the yarn 906 and MD and CD tapes 902, and a third layer that is the top
layer 920.
[00104]
The protective drainage wrap 900 of FIG. 9A is shaped to include embossed
channels 910. When installed between sheathing and siding, the embossed
channels 910 can
provide space between adjacent portions of the barrier layer 908 and the
sheathing that
promotes air drying of the protective drainage wrap 900.
[00105]
The embodiment depicted in FIG. 9A also features a material barrier
protection
system employing channels 910 in the CD direction in correspondence with the
troughs 922 in
the top layer 920. The channels 910 may be created by an embossing process
directed at
selected tape elements in the CD direction. Such embossing may occur before
weaving, during
weaving, or after weaving. The channels 910 and troughs 922 increase the
drainage capacity
of the wrap and increase the surface area available for water exposure or
collection, which
facilitates air drying.
[00106]
The embodiment of FIG. 9B is substantially identical to that of FIG. 9A
with
the exception that the protective drainage wrap 900 in FIG. 9B does not
include any embossing.
FIG. 9A is a simplified at least partially exploded view showing the barrier
layer 908 spaced
apart from the base web; however, the barrier layer may be laminated directly
onto the base
web.
Nonwoven Sheet
[00107]
Some embodiments include a material layer positioned on the barrier layer
such
that the barrier layer is positioned between the material layer and the cross-
woven base web.
As such, when installed, the material layer is engaged with the sheathing of
the structure. The
embodiment shown in FIG. 9C includes a material layer, nonwoven sheet 924,
positioned
beneath the barrier layer 908. The nonwoven sheet 924 can provide additional
protection from
moisture and heat to the underlying structure, and can provide protection to
the barrier layer
908. For example, the nonwoven sheet 924 can protect the barrier layer 908
from mechanical
(e.g., abrasion) damage, such as preventing rupture or tear of the barrier
layer 908 during
manufacturing, handling, and/or installation.
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[00108]
In addition to providing protection from physical damage to the barrier
layer
908, the presence of the nonwoven sheet 924 reduces the strength requirements
for the barrier
layer 908. For example, a barrier layer 908 of a lower basis weight and/or a
thinner barrier
layer 908 can be used with the nonwoven sheet 924 in comparison to the basis
weight and/or
thickness that would be required if the nonwoven sheet 924 were not present.
For example,
relatively thicker barrier layers are typically recommended in order to
protect against damage
to the barrier layer, such as from handling or installation. However, the
protection of the
nonwoven sheet 924 allows for a relatively thinner barrier layer to be used.
The use of thinner
barrier layers increases the breathability (vapor permeability) of the barrier
layer. While the
embodiment shown in FIG. 9C lacks the top layer shown in FIGS. 9A and 9B, in
some
embodiments a top layer and a bottom material layer can be combined in a
multilayer laminate
construction.
1001091
When installed, the presence of the nonwoven sheet 924 results in the
barrier
layer 908 being spaced-apart or gapped from the underlying sheathing. The
nonwoven sheet
924 can be an open fibrous network of polymeric fibers, such that the nonwoven
sheet 924 has
void space therein. The additional space or gap between the barrier layer 908
and the sheathing,
combined with the additional void space within the nonwoven sheet 924,
protects the
underlying sheathing from moisture contact and provides for enhanced air
drying, such as
during humid conditions.
1001101
One particular embodiment of a multilayer laminate construction is a tri-
layer
protective drainage wrap that includes a cross-woven base web (bases weight 55
gsm) with a
monolithic breathable barrier layer (basis weight 20 ¨ 22 gsm) on a bottom
surface thereof and
a spunbond top layer (basis weight 10 gsm) on a front side of the cross-woven
base web. In
some embodiments, the basis weight of the tri-layer protective drainage wrap
is from 45 to 300
gsm, or from 100 to 250 gsm, or from 150 to 200 gsm, such as 135 gsm. In some
embodiments,
the basis weight of the cross-woven base web is from 30 to 200 gsm, or from 50
to 150 gsm,
or from 75 to 125 gsm, or preferably from 50 to 75 gsm. In some embodiments,
the basis
weight of the barrier layer is from 5 to 75 gsm, or from 15 to 65 gsm, or from
25 to 55 gsm, or
preferably from 20 to 30 gsm. In some embodiments, the basis weight of the
nonwoven sheet
(bottom material layer) is from 8 to 100 gsm, or from 20 to 80 gsm, or from 30
to 70 gsm, or
from 40 to 60 gsm, or preferably from 10 to 15 gsm. The breathable barrier
layer and the
spunbond nonwoven sheet can be laminated together and/or to the cross-woven
base web using
an adhesive, for example.
Protective Wraps with Hydrophilic MD Tape
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[00111]
In some embodiments, the protective drainage wraps include hydrophilic MD
tapes. With reference to FIGS. 10A and 10B, protective drainage wrap 1000
includes
hydrophobic CD tape 1002, a first portion of hydrophobic MD tape 1004a, a
second portion of
hydrophilic MD tape 1004b, yarn 1006, and a barrier layer 1008. The
hydrophilic MD tapes
1004b can facilitate the spread of liquid in the MD direction towards the yams
1006. That is,
liquid water between the yarns can be transported via the hydrophilic MD tapes
1004b to the
yarns 1006.
[00112]
In the embodiment of FIG. 10A, the base web does not include a CD tape
situated beneath the length of the yarn 1006. In more preferred embodiments,
such a CD tape
is installed and may be placed beneath yam across the entire base web such
that the yam is
placed above the CD tape material and protected thereby across the entire CD
length of the
base web. In this way, proximity between the hydrophilic MD tapes and the yarn
in FIG. 10A
is maintained. Most preferably, the CD tape is interwoven or interlaced with
the base web,
including the MD tapes and, as necessary, provided with hydrophilic sections
which are then
located adjacent the yarn and/or the CD tape is made entirely hydrophilic
material.
Protective Drainage Wrap Installation
[00113]
With reference to FIG. 2A, the installation of one exemplary protective
drainage
wrap in a building is depicted. Building 2000 includes sheathing 2004 and
siding 2002 (e.g.,
brick). Protective drainage wrap 200 is installed between the sheathing 2004
and siding 2002.
For example, the protective drainage wrap 200 can be stapled, nailed, screwed,
or otherwise
fastened or adhered to the sheathing 2004, and the siding 2002 can then be
installed over the
protective drainage wrap 200.
[00114]
The protective drainage wrap 200 is the same as or substantially similar to
the
protective drainage wrap shown in FIG. 3B. The protective drainage wrap 200
includes base
layer 208, CD tapes 202, MD tapes (not shown), and yarn 206. In the embodiment
depicted in
FIG. 2A, the protective drainage wrap 200 is embossed such that the base layer
208 includes
troughs 209 that define channels 210. When installed, the presence of the
troughs 209 in the
base layer 208 results in the raising of portions of the base layer 208 away
from the underlying
sheathing 2004. Thus, the troughs 209 provide for backside air gaps 2006 (or
air channels)
between portions of the base layer 208 and the underlying sheathing 2004.
These air gaps 2006
facilitate air drying and also keep portions of the base layer 208 spaced-
apart from the sheathing
2004, further protecting the building from moisture.
[00115]
On the front side of the protective drainage wrap 200, i.e., the side
facing the
siding 2002, the protective drainage wrap 200 includes yarns 206. The yams 206
are capillary-
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driven drainage elements that draw water downward in a drainage direction. The
channels 210
on the front side of the protective drainage wrap 200 provide flow paths for
liquid that is not
taken up by the yams 206. The yams 206 are at least partially raised above the
CD tapes 202
and have a thickness that is sufficient to form a space between the siding
2002 and the CD
tapes 202, providing front-side air gaps 2008. These air gaps 2008 facilitate
air drying and
keep portions of the protective drainage wrap 200 spaced-apart from the siding
2002.
[00116]
FIG. 2A shows some of the vapor transmission paths 2009 through the wrap
200 as well as liquid wicking paths 2011 into the yams 206. While these paths
are not called
out in FIG. 2B, the same or similar paths can be present in the embodiment of
FIG. 2B.
Furthermore, these paths are for exemplary purposes only and are not intended
to be limiting.
[00117]
With reference to FIG. 2B, the installation of another exemplary protective
drainage wrap in a building is depicted. Building 2000 includes sheathing 2004
and siding
2002 (e.g, brick). Protective drainage wrap 200 is installed between the
sheathing 2004 and
siding 2002, and is substantially the same as that shown in FIG. 2A, but with
the addition of
the top layer 920 of nonwoven with the ridges 922 formed via creping. The yams
206 are at
least partially raised above the CD tapes 202 and of a thickness that is
sufficient to form a space
between the siding 2002 and the CD tapes 202, providing front-side air gaps
2008 between the
top layer 222 and the siding 2002 and additional front-side air gaps 2008
between the top layer
222 and the CD tapes 202. These air gaps 2008 facilitate air drying and keep
portions of the
protective drainage wrap 200 spaced-apart from the siding 2002. FIGS. 2A and
2B are
simplified at least partially exploded views showing the barrier layer 208
spaced apart from the
base web; however, the barrier layer may be laminated directly onto the base
web.
[00118]
FIGS. 2A and 2B (and the cross-sectional illustrations of FIGS. 3A-10B)
provide simplified illustrations showing the various components of described
systems, and, to
some degree, their physical relations and juxtapositions. The illustrations
are not to scale and
are not precise representations. For clarity and to facilitate descriptions,
the components are
sometime drawn, to a slight degree, in exaggerated fashion and/or exploded
perspective. This
is particularly true of relatively thin layers or close fit mutually-embossed
components or layers
in the various multi-layer constructions and embodiments described herein.
(See e.g., FIGS.
3A, 4A, 5A, 6A, ) The plan views of FIGS. 3A, 4A, 5A, 6A, 7A, 8A, and 10A are
simplified
illustrations showing the various components of described systems, and, to
some degree, their
physical relations and juxtapositions. The illustrations are not to scale and
are not precise
representations, and some features, such as troughs may not be viewable in
such plan views.
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[00119]
FIG. 14 is an exploded view of an installation. Installation 1401 includes
sheathing 1403, siding 1405, and protective drainage wrap 1400. Protective
drainage wrap
1400 is the same as or similar to the wrap shown in FIG. SA. Wrap 1400
includes yarns 1406,
hydrophobic MD tape 1404, hydrophobic CD tapes 1402a, hydrophilic CD tapes
1402b, and
hydrophilic CD tapes 1402c. The yarns 1406 are more hydrophilic than the CD
tapes 1402b,
and the CD tapes 1402b are more hydrophilic than the CD tapes 1402c. The wrap
1400 is
vapor permeable such that vapor 1409 passes therethrough. The wrap 1400 is
liquid
impermeable such that liquid water drains in a drainage direction 1404, such
as via capillary
action in yarns 1406.
Additional Aspects and Variations
[00120]
The present disclosure introduces certain and discrete features or
improvements
that may be incorporated, individually or in combination, into the barrier
protection systems
and/or the protective drainage wraps incorporating a basic interlaced web or
fabric with
advantageous affect. The additions or modification can achieve structural and
performance
benefits. To illustrate, the presently available drainage wrap known in the
industry may readily
adopt the following features or modifications: (1) use of a yarn with a higher
modulus
(maximize protrusion front and back of sheet); (2) use of yarn made of multi-
lobal shaped
fibers in the yarn for enhanced fluid flow and capillarity; (3) use of yarn
supported on
hydrophobic or hydrophilic CD tapes; (4) use of hydrophobic CD tapes,
hydrophilic CD tapes
or a combination thereof; (5) use of hydrophobic MD tapes, hydrophilic MD
tapes or a
combination thereof (6) use of creped CD and/or MD tapes; (7) embossing CD
and/or MD
tapes to form channels; (8) supporting yam between or within embossed
channels; (9) use of
CD tapes having gradient hydrophilicity; (10) use of a top layer of creped or
embossed material
for 3D topography; (11) use of a bottom layer of a nonwoven material; (11)
modifying and/or
selecting material or elements to present patterned wettability for enhanced
drainage flow; (12)
combining hydrophilic and hydrophobic elements for wettability control and
water flow
enhancement; (13) use of embossed troughs positioned to provide spacing
between the wrap
and an adjacent structure; (14) multi-laminate structures with a desir3ed
surface topography;
or (15) combinations thereof
1001211
in one aspect of the present disclosure, a material harrier systems,
apparatus, or
product is provided which incorporates a substantially continuous or
contiguous fabric or
Han ket constructed of at least two sets of correlanng members (MD and CD
tapes) preferably
adjoined in cross-relation. Such a construction of multiple structural
elements exhibiting
thickness and surface area may be referred to as a 'web.- Typically, two sets
of tapes or panels
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of boards --- structural members contiibuting to the surface area or make up
of the web - are
arranged along intersecting lines to make a network ¨ the fabric or blanket.
More preferably,
the two tape members are disposed in transverse relation (e.g., perpendicular
or generally
perpendicular) and most preferably, adjoined as a cross-laminate or interlaced
such as in a
weave. See e.g. FIGS. 1-3 in 6 in U.S. Pat. 6,761,006 (which Figures and
accompanying
descriptions have been incorporated herein and made a part of the present
disclosure). For
purposes of the present description, such a construction may be referred to
generally as a fabric
or blanket, and is considered contiguous or continuous as when the cross-
members are
generally and relatively disposed to define a continuous or contiguous area or
surface (of the
web) within its perimeter that is, preferably, substantially or generally (but
not necessarily,
completely) free of voids, holes, gaps, or spaces between members.
[00122]
In one aspect, such a material, barrier systems, apparatus, or product a
system or
barrier is provided that incorporates cross-woven or cross-laminate materials
as an integral
layer, and, preferably, a layered portion comprising such cross-laminate or
cross-woven
materials.
[00123]
In one aspect, the present disclosure presents a protective drainage wrap
comprising a cross-woven base layer or fabric with a preferably breathable
solid layer portion
and characterized by enhanced drainage functionality. In one embodiment, the
barrier
protection system is equipped with oriented drainage channels and the system
utilize
capillarity-driven flow mechanisms in addition to gravity-driven flow in the
traditional
drainage regions. In one variation, the capillarity-driven drainage elements
are elongated
elements such as cords or yarns preferably comprised of hydrophilic, multi-
lobal shaped fibers
to accommodate higher fluid flows and compression resistance for maintaining
overall
drainage volume in the system. Furthermore, appropriate surface wettabilities
may be provided
to create paths to feed the wicking yarns
1001241
In another aspect, the present disclosure presents a barrier protection
system,
including a protective drainage wrap, having a three-dimensional structure,
either one or two-
sided. In preferred embodiments, three-dimensional features or characteristics
of the system
provides for and maintains the desired drainage volume. This volume also
contributes to
evaporative drying due to air circulation. Further, in these embodiments, the
desired three-
dimensional feature is created by the yarn and/or by surface topography,
introduced by such
mechanism as embossing, for example.
[00125]
In another aspect, a material barrier construction is provided comprising a
base
web equipped with a drainage surface and, further, drainage channels for
quickly passing water
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and moisture downward from the system and from building surfaces, inducing
primarily by
gravity-driven flow. In a further aspect, the material barrier construction is
provided with
elongated hydrophilic structural elements that act as conduit for passing
water or moisture
drawn into the structural element. In a further aspect, the structural element
is a structural
element incorporated into and made a part of the base web, and at least partly
defines the cross-
section of the web and the drainage surfaces of the system, while also
presenting a conduit for
capillary-driven and/or gravity-driven flow to add to and assist the system's
drainage
capabilities. The present disclosure further provides material selection and
structural options
(e.g., modifications) to enhance the conduit/structural elements drainage
functionality (e.g., the
wicking mechanism and capillary flow mechanism inherent in the structure).
[00126]
In another aspect, a protective drainage wrap is provided having a multi-
laminate structure (preferably tri-laminate). In one variation, the barrier
protection system
incorporates a top layer of sheet with topography of appropriately oriented
drainage channels.
The full sheet may be creped or embossed spunbond, nonwovens or film.
[00127]
In another aspect, a material barrier construction is disclosed having a
first
portion comprising a fabric cross-woven or cross-laminate material, a coating
making up a
second portion. Preferably, the coating includes a polyolefin, polyester,
nylon, ethylene vinyl
alcohol, or combinations thereof, and the first and second portions being
disposed adjacent
each other. In some embodiments, the layer 908 provides a liquid barrier and
is a microporous
layer or a monolithic layer that is capable of allowing water vapor to pass
there-through.
[00128]
The smart vapor retarder can be in the form of a coating or film. The smart
vapor retarder can be configured to have a water moisture vapor permeability
that varies in
direct relationship with increases and/or decreases of ambient humidity
conditions. Such water
moisture vapor permeability transformation allows for drying to occur through
the process of
vapor diffusion; thereby, improving the speed of drying of the insulation and
building
materials. The coating or film allows trapped moisture to escape, thereby
alleviating a
consequent formation of mold and water damage typically resulting from excess
trapped
moisture. Some exemplary smart vapor retarders include those described in
United States
Patent Nos. 6,890,666; 6.878.455; and 6,808,772; and United States Patent
Application No.
2007/0015424. In some embodiments, when relative humidity is low, the smart
vapor retarder
provides high resistance to vapor penetration from the interior, and when
relative humidity
increases the permeance of the smart vapor retarder increases, thus allowing
water vapor to
pass through, which facilitates drying. For example, the material of the smart
vapor retarder
can swell and become porous upon contact with moisture.
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[00129]
In one exemplary embodiment, the base layer is a smart vapor retarder that
provides permeance to water vapor that increases with ambient relative
humidity, and can be
advantageous in relatively quick drying walls. The smart vapor retarder can be
a coating or
layer that includes nylon, ethylene vinyl alcohol (EVOH) or copolymers thereof
In some
embodiments, one or more of the CD and/or MD tapes are made of such smart
vapor retarder
materials.
[00130]
In specific embodiments, the fabric is made up of a network of a first
material
and a second material. The first material has a first thickness and is
oriented in the machine
(i.e., relative to and transverse to a downstream or direction of drainage (or
vertical) when
installed) including a polyolefin, polyester, nylon or combinations thereof,
the machine
direction material. Preferably, the material in the other direction (cross-
machine, transverse or
direction of drainage) includes a polyolefin, polyester, nylon or combinations
thereof, and is
characterized by a second thickness. In a further aspect, this second
thickness is at least two
times greater than the first thickness so as to assist in providing drainage
for moisture build-
up. The present disclosure provides various improvements to this basic design,
including in
the selection of materials for system components, their geometry and
topography, and
modification to material surfaces.
Methods of Making and Installing the Protective Drainage Wrap
[00131]
Embodiments of the present disclosure include methods of making and
installing the protective drainage wraps disclosed herein. With reference to
FIG. II, a method
1100 of forming the wrap is depicted.
[00132]
The method can include a material selection step 1102. The material
selection
can include selecting materials for the CD tape, MD tape, yarn, backing layer,
top layer, or
combinations thereof. The CD and MD tapes can be selected to have a desired
hydrophobicity
and/or hydrophilicity. The yarn can be selected to have a desired non-circular
cross section.
1001331
In the embodiments where yarn is supported by a CD tape, the yarn and the
tape
can be combined by appropriate layering at element 1388 prior to feeding the
layered structure
into the loom for weaving.
[00134]
The method can include an embossing step 1104 that includes embossing
selected weft (CD tapes) of the cross-woven web. For example, the selected CD
tapes can be
embossed as the CD tapes are being unwound from a spool to feed to the shuttle
during the
weaving process. In embodiments in which the yarn is supported (e.g., nestled)
on an embossed
CD tape, the yarn can be sourced from a spool and can be laid into the
embossed trough of the
CD tape after the embossing of the CD tape has been performed. In some
embodiments, the
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tapes are embossed before weaving. In other embodiments, the tapes are
embossed after
weaving. The tapes can be made of a thermoplastic material, such that the
embossing can be
accomplished using a die with heat and pressure. In embodiments where CD tapes
positioned
between yarn elements are embossed, the embossing can be performed either
before or after
weaving by passing the CD tape material through an embossing unit. In some
embodiments
when the tape is embossed after weaving, the embossing is performed prior to
the prior to the
addition of the base layer. The embossing provides both drainage channels at
the front side of
the protective drainage wrap and protrusions at the back side of the
protective drainage wrap
for added back spacing to promote air drying.
[00135]
The method can include a creping step 1106, including creping at least some
of
the MD tapes of the cross-woven web. For example, the tapes can be creped
prior to the
weaving process, such as by passing the tapes through a crepe unit prior to
passing the tapes to
the loom. The creping can be performed on the MD tapes such that the
orientation of the
creping ridges in the MD tape is directed downward, in the CD direction, and
such that the
drainage is directed to flow downwards. Some examples of creped spunbond are
described in
U.S. Patent Nos. 6,197,404; and 6,838,154. In some embodiments, Micrex can be
applied to
film creping. See U.S. Patent No. 3,260,778.
[00136]
The method can include a yarn extrusion step 1108, including extruding a
polymer melt from a die to produce a continuous synthetic yarn having a non-
circular cross-
section.
[00137]
The method can include a hydrophilicity treatment step 1110. In embodiments
where some of the tapes are hydrophilic and some are hydrophobic, a first
spool can be used
to dispense the hydrophilic material and a second spool can be used to
dispense the
hydrophobic material. In some embodiments, the materials used as the tapes are
selected such
that the materials exhibit the desired properties (e.g., hydrophobicity or
hydrophilicity). In
other embodiments, materials are treated to provide the materials with the
desired properties.
For example, a hydrophobic material can be subjected to in situ
hydrophilization (e.g., by
treating the tapes) prior to the weaving process. A material that is subjected
to hydrophilization
is referred to herein as a hydrophilized material. A hydrophilized material
exhibits increased
hydrophilicity after hydrophilization relative to the hydrophilicity of the
material prior to
hydrophilization.
[00138]
The hydrophili city or hydrophobicity of the tapes can be a result of the
polymer
type and composition (e.g., material additives added to the polymer melt) of
the tapes or of
external treatment of the tapes. Some exemplary hydrophilic (contact angle <
90 degrees)
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polymer types are EVOH (48), PVOH (51), Nylon 6,6 (68), and PET (73). Some
exemplary
hydrophobic (contact angle > 90 degrees) polymer types are PE (96) and PP
(102). Some
exemplary hydrophilizing additives are Irgasurf PF3155 and Techsurf PPM15560.
The
additives can be added to the polymer melt to confer hydrophilicity to
hydrophobic polymers.
For example, hydrophilization of polypropylene can be achieved with a mixture
of various
ethoxylated alcohols of structure CH3-CH2-(CH2-CH2)m-CH2CH2-(OCH2CH2)n-OH
where m
is between 9 and 35 and n is between 1 and 10. Other additives that can be
used for the
hydrophilization of a surface include organosilicones, polyethylene glycols,
fatty acid
monoglycerides or alkoxylated alkyl phenols. An exemplary hydrophilic
masterbatch for
polypropylene is one sold by Polyvel under the trade name VW-351. An exemplary
hydrophobic additive is Goulston Hydrepel, which can be used to increase the
hydrophobicity
of polymers, such as polypropylene. Exemplary external treatments that can be
used to provide
hydrophilicity include plasma treatment and corona treatment. Plasma treatment
is effective
at increasing hydrophilic properties. In some embodiments, the method includes
providing for
a gradient hydrophilicity, such that the hydrophilicity of the yarn elements
are greater than the
hydrophilicity of the CD tape beneath the yarn, and such that the
hydrophilicity of the CD tapes
are progressively less hydrophilic the further from a yarn they are
positioned.
[00139]
The method can include forming the cross-woven web. Formation of the cross
woven web can include a weaving step 1112 that includes weaving together a
plurality of CD
tape with a plurality of MD tape and a plurality of yarn elements extending in
the CD direction.
The weaving process can be performed using a flat loom, for example. In some
embodiments,
the yarn is inserted in the CD direction using a shuttle. When weaving the
yarn into the cross-
woven base web, the method can include positioning the strands of yarn onto a
CD tape.
[00140]
The method can include barrier step 1114 including providing a barrier
layer
onto the back side of the cross-woven web. For example, the barrier layer can
be a breathable
coating, such as a microporous film, that is bonded to the back of the cross-
woven web using
hot melt.
[00141]
The method can include covering step 1116 including providing atop layer
onto
the front side of the cross-woven web. For example, the top layer can be a
creped spunbond
nonwoven, and can be attached to the cross-woven web and/or the backing layer.
1001421
Some embodiments include a method of installing a protective drainage wrap.
FIG. 12 is a flow chart of a method 1200 of installing a protective drainage
wrap. Method 1200
can include providing a protective drainage wrap, step 1202. The protective
drainage wrap can
be in accordance with any of the protective drainage wraps disclosed herein.
The method can
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include attaching the protective drainage wrap to sheathing of structure, step
1204. The
attaching can be performed via stapling, nailing, screwing or otherwise
securing the protective
drainage wrap to the sheathing. The method can include attaching siding to the
structure such
that the protective drainage wrap is positioned between the siding and the
sheathing, step 1206.
The protective drainage wrap can be positioned to provide various air channels
between the
protective drainage wrap and the sheathing and between the protective drainage
wrap and the
siding.
1001431
FIG. 13 is a simplified diagram of a system configured to manufacture the
protective drainage wrap disclosed herein. System 1399 includes spool 1397 for
dispensing
CD tape 1302, spool 1395 for dispensing MD tape 1304, and spool 1393 for
dispensing yarn
1306. Each of the CD tape 1302, MD tape 1304, and yarn 1306 are dispensed to
the loom
1391. Prior to passing to the loom 1391, CD tape 1302 passes through an
embossing unit 1387
to emboss the CD tape 1302. Prior to passing to the loom 1391, MD tape 1304
passes through
a creping unit 1385 to crepe the MD tape 1304. The loom 1391 operates to weave
the CD tape
1302, MD tape 1304, and yarn 1306 together to form the cross-woven base web
1383 with yarn
1306. The cross-woven base web 1383 is coupled with the barrier layer 1308
dispensed from
spool 1389, nonwoven sheet 1394 dispensed from spool 1379, and top layer 1320
dispensed
from spool 1377. The protective drainage wrap 1300 can then be optionally
subjected to post-
treatments 1375 prior to recovery of the protective house wrap 1300. The post-
treatments 1375
can include embossing, creping, or other processes.
1001441
The foregoing has been presented for purposes of illustration and
description. These descriptions are not intended to limit the disclosure or
aspects of the
disclosure to the specific barrier protection systems or system components,
constructions or
articles, apparatus and processes disclosed. Various aspects of the disclosure
are intended for
applications other than the specific systems, constructions and fabrics
referred to
above. Certain manufacturing techniques and structural features and designs
described may
also be incorporated into or with other barrier protection systems, and other
weather resistant
material systems incorporating fabrics and layers, assemblies, or combinations
thereof The
specific systems described may also incorporate different components in
alternate designs
according to the present description. These and other variations of the
disclosure will become
apparent to one generally skilled in the relevant building and construction
trade and art, when
provided with the present disclosure. Consequently, variations and
modifications
commensurate with the above teachings, and the skill and knowledge of the
relevant art, are
within the scope of the present disclosure. The embodiments described and
illustrated herein
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are further intended to explain best or preferred modes for practicing the
disclosure, and to
enable others skilled in the art to utilize the disclosure and other
embodiments and with various
modifications required by the particular applications or uses of the present
disclosure.
[00145]
Although the present embodiments and advantages have been described in
detail, it should be understood that various changes, substitutions and
alterations can be made
herein without departing from the spirit and scope of the disclosure.
Moreover, the scope of
the present application is not intended to be limited to the particular
embodiments of the
systems, process, machine, manufacture, composition of matter, means, methods
and steps
described in the specification. As one of ordinary skill in the art will
readily appreciate from
the disclosure, processes, machines, manufacture, compositions of matter,
means, methods, or
steps, presently existing or later to be developed that perform substantially
the same function
or achieve substantially the same result as the corresponding embodiments
described herein
may be utilized according to the present disclosure. Accordingly, the appended
claims are
intended to include within their scope such processes, machines, manufacture,
compositions of
matter, means, methods, or steps.
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